Insulation compaction device and method for forming an insulated structure for an appliance

ABSTRACT

A method for forming an insulative member includes forming a wrapper for an insulating structure, the wrapper defining an insulating cavity. A predetermined amount of an insulating media is disposed into the insulating cavity, the insulating media having a pre-compaction density. The insulating media is modified to define a desired insulation density by applying a positive compression to and generating a negative compression within the insulating media during a simultaneous compression phase. At least the simultaneous compression phase is operated until the insulating media reaches a desired insulation density, the desired insulation density being greater than the pre-compaction density. The insulating cavity is sealed to maintain the desired insulation density of the insulation media within the insulating cavity to form the insulating structure.

BACKGROUND

The device is in the field of insulating structures for appliances, specifically, an insulating structure for an appliance having a compacted insulating material within the insulating structure.

SUMMARY

In at least one aspect, an insulation compaction device for installing an insulating media within an insulating structure of an appliance includes a piston chamber having a sidewall and a base that define an internal cavity. An operable piston selectively engages the sidewall to selectively define a hermetic seal between the operable piston and the piston chamber, wherein the operable piston is operable to define a selected chamber volume of the internal cavity defined between the operable piston and the piston chamber. A valve is positioned proximate the base, the valve defining selective communication between the internal cavity and an exterior of the piston chamber, wherein the valve is selectively operable in a passive state to release gas disposed within the piston chamber to the exterior, wherein the passive state is defined by an equalized pressure within the piston chamber during operation of the operable piston to define the selected chamber volume. A pump mechanism is in communication with the piston chamber via the valve to define an active state of the valve, wherein selective operation of the pump mechanism places the valve in the active state to define a chamber pressure of the internal cavity, the chamber pressure being less than the equalized pressure, and wherein the operable piston and the pump mechanism are at least one of individually operable and simultaneously operable to define a selected piston chamber environment defined by the selected chamber volume and one of the equalized pressure and chamber pressure.

In at least another aspect, a method for forming an appliance cabinet includes forming an insulating cavity between an inner liner and an outer wrapper of an appliance, wherein the inner liner and the outer wrapper define walls of the appliance and the insulating cavity is partially defined between the inner liner and the outer wrapper. A gas valve is disposed within at least one of the inner liner and outer wrapper, the gas valve defining a selective communication between the insulating cavity and an exterior of the appliance. A gas pump is disposed in communication with the gas valve, wherein the gas pump is in communication with the insulating cavity via the gas valve. An operable piston is slidably operable against the outer wrapper, wherein selective engagement between the operable piston and the outer wrapper defines a hermetic seal. A predetermined amount of an insulation media is disposed within the insulating cavity. The operable piston is disposed within the outer wrapper. At least one of the operable piston and the gas pump is operated to define a selected insulating cavity environment that corresponds to a desired insulation density, wherein the operable piston operates to a predetermined location relative to the outer wrapper to define a selected insulating cavity volume, and wherein the gas pump is operated to define a selected insulating cavity pressure, wherein the selected insulating cavity volume and the selected insulating cavity pressure define the selected insulating cavity environment within which the insulating media is maintained at the desired insulation density.

In at least another aspect, a method for forming an insulative member includes forming a wrapper for an insulating structure, the wrapper defining an insulating cavity. A predetermined amount of an insulating media is disposed into the insulating cavity, the insulating media having a pre-compaction density. The insulating media is modified to define a desired insulation density by applying a positive compression to and generating a negative compression within the insulating media during a simultaneous compression phase. At least the simultaneous compression phase is operated until the insulating media reaches a desired insulation density, the desired insulation density being greater than the pre-compaction density. The insulating cavity is sealed to maintain the desired insulation density of the insulating media within the insulating cavity to form the insulating structure.

These and other features, advantages, and objects of the present device will be further understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front perspective view of an appliance incorporating an aspect of the compacted insulated structure;

FIG. 2 is a perspective view of an exemplary insulation compaction device incorporating positive and negative compressive forces;

FIG. 3 is a side perspective view of the insulation compaction device of FIG. 2 looking into the internal cavity of the piston chamber;

FIG. 4 is a cross-sectional view of the insulation compaction device of FIG. 2 taken along line IV-IV;

FIG. 5 is a cross-sectional view of an aspect of the insulation compaction device showing the gas valve operating in a passive state;

FIG. 6 is a cross-sectional view of the insulation compaction device of FIG. 5 showing the gas valve operating in an active state;

FIG. 7 is a cross-sectional view of the insulation compaction device of FIG. 5 showing simultaneous operation of the piston and the gas valve;

FIG. 8 is a top perspective view of an exemplary insulating structure for an appliance incorporating an aspect of the insulation compaction device;

FIG. 9 is a cross-sectional view of the insulation compaction device of FIG. 8 taken along line IX-IX;

FIG. 10 is a schematic flow diagram illustrating an exemplary method for forming an insulative member; and

FIG. 11 is a schematic flow diagram illustrating an exemplary method for forming an appliance cabinet utilizing aspects of the insulation compaction device.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the device as oriented in FIG. 1. However, it is to be understood that the device may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

As illustrated in FIGS. 1-7, an insulation compaction device 10 can be used to increase the density of an insulating media 12 or insulating material for installation within an insulating internal cavity 14 of an appliance 18, such as that typically formed within the walls 16 of the appliance 18. Such appliances 18 can include, but are not limited to, refrigerators, freezers, dishwashers, ovens, laundry appliances, water heaters, HVAC systems, and other similar household appliances. FIGS. 2-7 exemplify various aspects of the insulation compaction device 10 for purposes of illustrating exemplary operational modes and methods of operation for aspects of the insulation compaction device 10. The insulation compaction device 10 is configured to prepare and/or dispose insulating media 12 within an insulating structure 20 of an appliance 18. The insulation compaction device 10 includes a piston chamber 22 having a sidewall 24 and a base 26 that defines an internal cavity 14 of the piston chamber 22. An operable piston 28 selectively engages the sidewall 24 wherein engagement between the operable piston 28 and the sidewall 24 defines a hermetic seal 30 between the operable piston 28 and the piston chamber 22. It is contemplated that the operable piston 28 is operable to define a selected chamber volume 32 of the internal cavity 14 defined between the operable piston 28 and piston chamber 22. The selected chamber volume 32 can be defined by one or more of various design, performance, and/or dimensional parameters of the insulating structure 20 for the appliance 18.

Referring again to aspects of the device as exemplified in FIGS. 2-7, a valve 40 is positioned proximate the base 26 of the piston chamber 22, where the valve 40 defines selective communication between the internal cavity 14 and the exterior 42 of the piston chamber 22. The valve 40 is selectively operable in a passive state 44 to release gas 46 disposed within the piston chamber 22 to the exterior 42. The passive state 44 of the valve 40 is defined by an equalized pressure 48 within the internal cavity 14 of the piston chamber 22 during operation of the operable piston 28 to define the selected chamber volume 32. In this manner, as the operable piston 28 moves to define the selected chamber volume 32, internal pressure within the internal cavity 14 increases due to the decrease in volume of the internal cavity 14. This increased pressure is released through the passive expression of gas 46 through the valve 40. The valve 40 is in a passive state 44 to provide for substantially equal pressure within the internal cavity 14 when compared with the exterior 42 of the piston chamber 22.

Referring again to FIGS. 2-7, a pump mechanism 60 is placed in communication with the piston chamber 22 via the valve 40 to define an active state 62 of the valve 40. Selective operation of the pump mechanism 60 places the valve 40 in the active state 62 to define a chamber pressure 64 of the internal cavity 14. It is contemplated that the chamber pressure 64 is different from, and typically less than, the equalized pressure 48. In this manner, operation of the pump mechanism 60, such as a gas pump, serves to create a low pressure region 66 within the internal cavity 14. This low pressure region 66 can be defined by an at least partial vacuum within the internal cavity 14 of the piston chamber 22. It is contemplated that the operable piston 28 and the pump mechanism 60 can be individually operable such that the operable piston 28 operates separately from the pump mechanism 60, either in a sequential pattern 70 or through operation of only one of the operable piston 28 and the pump mechanism 60. Alternatively, the operable piston 28 and the pump mechanism 60 can operate in a simultaneous pattern 72, such that a positive compressive force 74 of the operable piston 28 can be exerted against an insulating media 12. At the same time, a low pressure or negative compressive force 76 can be exerted against the insulating media 12 by the operation of the pump mechanism 60, to remove gas 46 from the internal cavity 14 through the valve 40 in the active state 62. It is contemplated that operation of the operable piston 28 and the pump mechanism 60, either independently, in the sequential pattern 70 or simultaneous pattern 72, serves to define a selected piston chamber environment 80 defined by the selected chamber volume 32 and one of the equalized pressure 48 and the chamber pressure 64.

Referring again to FIGS. 2-7, the insulation compaction device 10 can also include a pressure sensor 90 that is placed in communication with the internal cavity 14 to measure the chamber pressure 64 within the internal cavity 14. It is contemplated that the pressure sensor 90 can be located proximate the valve 40, proximate the pump mechanism 60, or at an external location while in communication with the internal cavity 14. The insulation compaction device 10 can also include a position sensor 92 in communication with the operable piston 28, and the piston chamber 22. The position sensor 92 is configured to measure the selected chamber volume 32 where movements of the operable piston 28 vary the amount of space or volume defined within the internal cavity 14. The pressure sensor 90 and the position sensor 92 can cooperate to communicate a current piston chamber environment 94 of the internal cavity 14.

According to the various embodiments, the current piston chamber environment 94 can be defined as the current volume 96 of the internal cavity 14 during operation of the operable piston 28 and also a current pressure 98 defined within the internal cavity 14 during operation of the valve 40 during the passive state 44 and/or the active state 62 of the valve 40 as the operable piston 28 and pump mechanism 60 operate to define the selected piston chamber environment 80. The pressure sensor 90 and position sensor 92 of the insulation compaction device 10 can communicate the pressure and position data to a processor 100, where the processor 100 calculates the current pressure 98 and the current volume 96. These calculations are combined to determine the current piston chamber environment 94. Once the current piston chamber environment 94 reaches the selected piston chamber environment 80, the operation of the operable piston 28 and the pump mechanism 60 can be interrupted such that the selected piston chamber environment 80 can be maintained within the internal cavity 14 until such time as the piston chamber 22 can be sealed. Once the piston chamber 22 is sealed, the operable piston 28 can be disengaged from the sidewall 24 and the pump mechanism 60 can be disengaged from the valve 40. In this manner, the selected piston chamber environment 80 can be maintained within the internal cavity 14 after manufacture and during use of the appliance 18.

Referring again to FIGS. 2-7, the operable piston 28 can include a back panel 110 engaged thereto. In such an embodiment, operation of the operable piston 28 locates the back panel 110 relative to the sidewall 24. Accordingly, the operable piston 28 moves to define the selected chamber volume 32 of the internal cavity 14 and, as a consequence, positions the back wall 16 relative to the sidewall 24. Once in the proper position to define the selected piston chamber environment 80, the sidewall 24 and back wall 16 can be engaged to one another through crimping, welding, fastening, adhesives, combinations thereof, and other attachment mechanisms to secure the back panel 110 to the sidewall 24 in order to maintain the selected piston chamber environment 80 within the internal cavity 14. In order to operate the operable piston 28 toward the position defining the selected chamber volume 32 of the internal cavity 14, the operable piston 28 can be moved by mechanical press 112, having various operational mechanisms that can include, but are not limited to, hydraulics, pneumatics, mechanical drives, screw drives, combinations thereof, and other similar operating mechanisms. The engagement between the back panel 110 and the sidewall 24 can define a sealed engagement, where the back panel 110 and sidewall 24 are attached to one another to define a hermetic seal 30.

Referring again to FIGS. 2-7, it is contemplated that the insulating media 12 can be placed within the internal cavity 14 before placing the operable piston 28 against the sidewall 24 of the piston chamber 22. It is also contemplated that a known amount of the insulating media 12 can be placed within the internal cavity 14 such that calculations based upon the selected chamber volume 32 and the chamber pressure 64 can be used to calculate a density of the one or more insulating materials that make up the insulating media 12. In this manner, the density of the insulating media 12 can be modified through operation of the operable piston 28 and the pump mechanism 60 in order to modify the density of the insulating media 12 to be substantially equal to a desired insulation density 120.

In the various embodiments, the desired insulation density 120 can be a density determined to provide a certain level of thermal and/or acoustical insulating properties to the insulating structure 20 of the appliance 18. It is further contemplated that the desired insulation density 120 can be determined during the design of the insulating structure 20 by incorporating various parameters, where such parameters can include, but are not limited to, cost of materials, production time, efficiency, performance, various dimensional parameters, combinations thereof and other similar parameters and considerations that may affect the design of a particular appliance 18 or an insulating structure 20 therefor.

Referring now to FIGS. 5 and 6, it is contemplated that the insulation compaction device 10 can operate such that the operable piston 28 and the pump mechanism 60 operate in a sequential pattern 70 and/or where only one of the operable piston 28 and the pump mechanism 60 operate to define the selected piston chamber environment 80. After the predetermined amount of the insulating media 12 is disposed within the internal cavity 14, the movement of the operable piston 28 to the selected chamber volume 32 can define a compressed state 130 of the insulating media 12 within the selected piston chamber environment 80. It is contemplated that the density of the insulating media 12 within the selected piston chamber environment 80 of the internal cavity 14 can correspond to the desired insulation density 120. As described above, where only the operable piston 28 is used to define the selected piston chamber environment 80, it is contemplated that the valve 40 operates in the passive state 44 to substantially equalize the pressure within the internal cavity 14, as related to the ambient air pressure around the exterior 42 of the piston chamber 22. In the passive state 44, gas 46 from within the internal cavity 14 is expelled from the internal cavity 14 via the valve 40 as the operable piston 28 moves to shrink the size of the internal cavity 14. It is also contemplated that where the operable piston 28 moves away from the base 26 of the piston chamber 22, thereby expanding the volume of the internal cavity 14, the valve 40 can be operated to allow the entry of gas 46 from the exterior 42 of the piston chamber 22 to again equalize the pressure between the internal cavity 14 and areas external to the piston chamber 22.

Referring now to FIG. 6, where the predetermined amount of insulating media 12 is disposed within the internal cavity 14, operation of the valve 40 in the active state 62, through operation of the pump mechanism 60, can serve to define the chamber pressure 64 of the internal cavity 14, corresponding to a low pressure state of the insulating media 12. This low pressure state of the insulating media 12 is defined within the selected piston chamber environment 80 that is set through operation of the pump mechanism 60 and the valve 40 in the active state 62. As discussed above, the selected piston chamber environment 80 includes the selected chamber volume 32 and the chamber pressure 64 that corresponds to the desired insulation density 120 of the insulating media 12 disposed within the internal cavity 14. During operation of the pump mechanism 60, by itself, the pump mechanism 60 draws gas 46 from the internal cavity 14 and expels this gas 46 to areas external of the piston chamber 22. It is contemplated that the creation of the low pressure areas within the internal cavity 14 through operation of the pump mechanism 60 can cause the operable piston 28 to move downward to passively equalize the pressure between the internal cavity 14 and areas external to the piston chamber 22. In such an embodiment, it is contemplated that the operable piston 28 can be placed in a fixed position that corresponds to the selected chamber volume 32 so that operation of the pump mechanism 60 can define the low pressure region 66 within the internal cavity 14 of the piston chamber 22. In this manner, operation of the pump mechanism 60 can serve to achieve the desired insulation density 120 of the insulating media 12 within the internal cavity 14.

According to various embodiments, it is contemplated that the pump mechanism 60 and valve 40 can work in conjunction with an insulating gas injection mechanism. In such an embodiment, as the pump mechanism 60 operates to draw gas 46 from the internal cavity 14 through the valve 40, a separate insulating gas injector injects an insulating gas into the internal cavity 14. In this manner, the expelled gas is replaced by an insulating gas. It is contemplated that the insulating gas can be held within the internal cavity 14 at the equalized pressure 48 or a different chamber pressure 64. It is further contemplated that the insulating gas can be any one of various insulating gasses that can include, but are not limited to, neon, carbon dioxide, xenon, krypton, combinations thereof and other similar insulating gasses.

Referring now to FIG. 7, as discussed above, it is contemplated that the operable piston 28 and the pump mechanism 60 can operate in a simultaneous pattern 72 to achieve the selected piston chamber environment 80, and, in turn, the desired insulation density 120 of the insulating media 12 within the internal cavity 14. Accordingly, the operable piston 28 can be moved toward a position that defines the selected chamber volume 32 and, at the same time, the pump mechanism 60 can be activated to draw gas 46 from the internal cavity 14 to create the low pressure region 66 of the insulating media 12 within the internal cavity 14. It has been discovered that sequential use of the positive compressive force 74, such as that provided by the operable piston 28, and the generation of a low pressure region 66 to create a negative compressive force 76, through operation of the pump mechanism 60, can efficiently achieve the desired insulation density 120 of the insulating media 12.

Additionally, simultaneous operation of the operable piston 28 and the pump mechanism 60 to achieve the desired insulation density 120 also provides an efficient mechanism for achieving a desired selected piston chamber environment 80, and in turn, the desired insulation density 120 of the insulating media 12 within the internal cavity 14. It is also contemplated that various phases of operation of the sequential and simultaneous patterns 72 for the insulation compaction device 10 can be implemented during formation of the insulating structure 20. These phases and patterns can include independent phases, sequential patterns 70, and simultaneous patterns 72 of operation of the insulation compaction device 10.

By way of example and not limitation, operation of the pump mechanism 60 removes gas 46 from the internal cavity 14. As this gas 46 is removed, the operation of the operable piston 28 can more effectively compress the insulating media 12 since there is less resistance, push back, rebound or other resistive force to oppose the positive compressive force 74 exerted by the operable piston 28. Accordingly, achievement of the selected piston chamber environment 80 and the desired insulation density 120 can be a more efficient process.

According to the various embodiments as exemplified in FIGS. 5 and 6, the independent phase of operation of the insulation compaction device 10 can be defined by operation of only one of the operable piston 28 and the pump mechanism 60 to define the selected piston chamber environment 80, and, in turn, the desired insulation density 120 of the insulating media 12 within the internal cavity 14. The sequential pattern 70 of operation of the insulation compaction device 10 can be defined by alternate operation of the operable piston 28 and the pump mechanism 60 to define the appropriate desired insulation density 120 for the insulating media 12.

Referring again to FIG. 7, the simultaneous pattern 72 of operation for the insulation compaction device 10, as discussed above, can be defined by simultaneous operation of the operable piston 28 and the pump mechanism 60 to define the desired insulation density 120 within the internal cavity 14 of the piston chamber 22. These phases and patterns can be implemented in a predetermined pattern during operation of the insulation compaction device 10 where the operation shifts between the sequential pattern 70 to the simultaneous pattern 72. It is contemplated that the use of the individual, sequential, and simultaneous patterns 72 of operation for the insulation compaction device 10 can be determined based upon several factors. Such factors can include, but are not limited to, the type of appliance, the size of the piston chamber 22, the thickness of the internal cavity 14, the composition of the insulating media 12, the desired insulation density 120, combinations thereof, and other similar factors.

According to the various embodiments, it is contemplated that the insulating media 12 can include various compositions and combinations of materials that can be used in conjunction with the insulation compaction device 10 for achieving the desired insulation density 120 within the internal cavity 14 of the piston chamber 22. Such materials can include silica, fumed silica, rice husk, glass spheres of varying size, and other similar primary insulating components. It is also contemplated that the insulating media 12 can include various getters, dessicants, opacifiers, carbon black, and other similar insulating compositions. These various compositions can be combined in varying combinations and proportions to achieve the desired characteristics for the insulating media 12 that, when used with the insulation compaction device 10, produces the desired insulation density 120 of the insulating media 12 within the internal cavity 14.

According to the various embodiments, various configurations of the insulating media 12 can have varying reactions to the positive and negative compressive forces 74, 76 exerted thereon. Certain insulating media 12 can experience varying degrees of rebound, where the insulating media 12 expands back toward its pre-compaction density 160 after being placed in the compressed state 130. In such situations, the back panel 110 of the insulating structure 20 should be able to be sealed to the sidewall 24 while the operable piston 28 defines the selected chamber volume 32. Release of the operable piston 28 may result in the rebound of the insulating media 12, forcing the back panel 110 away from this piston such that the selected chamber volume 32 and the desired insulation density 120 may not be achieved.

Referring now to FIGS. 8 and 9, it is contemplated that the piston chamber 22 for the insulation compaction device 10 can include an outer wrapper 140 and an inner liner 142 that define walls 16 of an insulating structure 20 for an appliance 18. The internal cavity 14 of the piston chamber 22 can be defined by the insulating internal cavity 14 within the walls 16 defined between the outer wrapper 140 and inner liner 142. It is contemplated that the embodiments exemplified in FIGS. 8 and 9 provide an aspect of the insulation compaction device 10 that incorporates the same operational aspects as those exemplified in FIGS. 2-7. In utilizing the insulation compaction device 10 within an insulating structure 20, such as a cabinet 145 for an appliance 18, the insulating media 12 can be disposed directly within the insulating internal cavity 14 defined between the outer wrapper 140 and inner liner 142 of the insulating structure 20 of the appliance 18. Accordingly, it is not necessary for an independent insulating structure 20, such as an insulating panel, to be manufactured and then later installed within the cabinet 145 of the appliance 18.

According to various embodiments, it is contemplated that the insulating media 12 can be disposed directly into the internal cavity 14 defined within the walls 16 of the insulating structure 20 and the operable piston 28, which includes the back panel 110 of the insulating structure 20, can be pressed downward to define the selected chamber volume 32 within the insulating internal cavity 14 of the walls 16 of the insulating structure 20. One or more valves 40 of the insulation compaction device 10 can be disposed within at least one of the outer wrapper 140 and inner liner 142, where the valves 40 can be connected to one or more pump mechanisms 60, to operate in the passive state 44 or the active state 62, to define the selected piston chamber environment 80 within the insulating internal cavity 14 of the insulating structure 20 of the appliance 18. Once the insulating media 12 is disposed within the insulating internal cavity 14 within the walls 16 of the insulating structure 20, the operable piston 28, having the back panel 110 of the insulating structure 20, can be disposed into engagement with the outer wrapper 140 of the insulating structure 20 to define a hermetic seal 30 between the back panel 110 and the outer wrapper 140. This hermetic seal 30 between the back panel 110 and the outer wrapper 140 allows the pump mechanism 60 to operate the valve 40 in the active state 62 to define a low pressure region 66 of an insulating media 12 within the insulating space of the insulating structure 20.

As discussed above, the operable piston 28 and the pump mechanism 60 of the insulation compaction device 10 can operate to form the insulating structure 20 through independent operation or operation of the sequential and/or simultaneous patterns 70, 72, and in varying combinations of these patterns, to generate the desired insulation density 120 of the insulating media 12 within the insulating internal cavity 14. Once the desired insulation density 120 is achieved, the back panel 110 can be sealed to the outer wrapper 140 to form a hermetic seal 30 between the back panel 110 and outer wrapper 140 to contain the selected piston chamber environment 80 within the internal cavity 14 and maintain the desired insulation density 120 of the insulative material within the selected piston chamber environment 80.

According to the various embodiments, it is contemplated that the use of the insulation compaction device 10 in combination with the insulating structure 20 of the appliance 18 can eliminate various steps of forming separate insulative panels or insulative components that are installed as separate pieces or a series of components within the insulating structure 20 of the appliance 18. Additionally, because the outer wrapper 140, inner liner 142, and back panel 110 can be sealed together to form a hermetic seal 30, various barrier films and internal sealing layers may not be necessary to maintain the desired insulation density 120 within the insulating internal cavity 14 of the insulating structure 20. It is contemplated that the outer wrapper 140, inner liner 142, and back panel 110 can be made of various materials that can include, but are not limited to, metal, metal alloy, polymer, composite materials, combinations thereof, and other similar materials that can create a hermetic seal 30 when bonded together to form the insulating structure 20 of the appliance 18.

According to the various embodiments, it is contemplated that the various aspects of the insulation compaction device 10 can be used to create various insulating structures 20. As discussed above, these insulating structures 20 can include a structural cabinet 145 for an appliance 18, where the insulating media 12 is directly disposed between the inner liner 142 and outer wrapper 140. It is also contemplated that the insulation compaction device 10 can be used to create smaller insulating units, such as insulating panels, that can be separately installed within a cabinet 145 of an appliance 18 to define an insulating structure 20 for the appliance 18.

Referring now to FIGS. 2-10, having described various aspects of the insulation compaction device 10, a method 400 for an aspect of forming an insulative member is described. The method 400 can include forming an outer wrapper 140 for an insulating structure 20 (step 402). It is contemplated that the outer wrapper 140 can define an insulating internal cavity 14 therein. After the outer wrapper 140 is formed, a predetermined amount of an insulating media 12 can be disposed within the insulating internal cavity 14 (step 404). It is contemplated that the insulating media 12 can have a pre-compaction density 160 that is defined within the insulating media 12 before any compressive forces of the operable piston 28 and the pump mechanism 60 are exerted thereon. According to various embodiments, the insulating media 12 can go through various compaction steps before being disposed within the insulating internal cavity 14 of the insulating media 12. Such compaction steps can be used to alter the physical composition of the insulating media 12 to define various particle sizes and compression strengths of the insulating media 12. Once the insulating media 12 is disposed within the insulating cavity, the insulating media 12 can be modified to define a desired insulation density 120 by applying a positive compressive force 74 to and generating a negative compressive force 76 within the insulating media 12 during a simultaneous pattern 72 of compression, or a simultaneous phase (step 406). As discussed above, the positive compressive force 74 applied to the insulating media 12 can be applied through the operation of the operable piston 28 to place the downward compressive force on the insulating media 12. It is contemplated that the operable piston 28 can include at least one sealing member 170 that is configured to engage the inner surface 172, outer surface 174, or both, of the outer wrapper 140. This engagement between the sealing member 170 of the operable piston 28 and the inner and/or outer surface 174 of the wrapper defines a hermetic seal 30 formed between the operable piston 28 and the wrapper of the insulating structure 20. This sealing engagement can serve to provide for the simultaneous pattern 72 of operation described herein.

Referring again to FIGS. 2-10, the operation of at least the simultaneous pattern 72 of the insulation compaction device 10 takes place until the insulating media 12 reaches the desired insulation density 120 (step 408). The desired insulation density 120 is typically greater than the pre-compaction density 160, such that application of the positive compression and negative compression serves to densify the insulating media 12. As discussed above, it is contemplated that the insulation compaction device 10 can include the simultaneous pattern 72, the sequential pattern 70, and independent patterns of operation that can work in various phases, sequences, and configurations to achieve the desired insulation density 120 of the insulating media 12.

As exemplified in FIGS. 1-10, once the desired insulation density 120 is achieved, the internal cavity 14 can be sealed to maintain the desired insulation density 120 of the insulating media 12, within the internal cavity 14 to form the insulating structure 20 (step 410).

According to the various embodiments, it is contemplated that the insulating structure 20 can be an appliance cabinet 145, where the insulating media 12 is disposed directly within the insulating internal cavity 14 of an appliance cabinet 145. It is also contemplated that the insulating structure 20 can be a separate insulating panel that can be installed as a unitary piece, or a series of panels, within a separate appliance cabinet 145. The use of a direct deposition of insulating material within the appliance cabinet 145 versus the installation of a premanufactured insulating member may depend upon the design of the appliance 18 and the specific parameters desired for the design and operation of the appliance 18.

Referring now to FIGS. 2-9 and 11, a method 600 for forming an aspect of an appliance cabinet 145 is also disclosed. Such a method 600 can include forming an internal cavity 14 between an inner liner 142 and outer wrapper 140 of an appliance 18 (step 602). As discussed above, the outer wrapper 140 and inner liner 142 can define walls 16 of an appliance cabinet 145 and the insulating internal cavity 14 can be at least partially defined between the outer wrapper 140 and inner liner 142. A gas valve can be disposed within at least one of the inner liner 142 and outer wrapper 140 (step 604). As discussed above, it is contemplated that the gas valve defines a selective communication between the insulating cavity and the exterior 42 of the appliance 18. Once the valve 40 is installed, a gas pump can be disposed in communication with the gas valve (step 606). The connection of the gas pump with the gas valve 40 can place the gas pump in communication with the insulating internal cavity 14 via the gas valve 40.

Referring again to FIGS. 2-9 and 11, an operable piston 28 can be provided, where the operable piston 28 is slidably operable against the outer wrapper 140 (step 608). Selective operation between the operable piston 28 and the outer wrapper 140 can define a hermetic seal 30. It is contemplated that the operable piston 28 can engage at least one of an inner surface 172 and an outer surface 174 of the outer wrapper 140. The engagement between the operable piston 28 and the outer wrapper 140 can depend upon the method of operation of the insulation compaction device 10. The operable piston 28 engaging the inner surface 172 of the outer wrapper 140 can serve to at least partially prevent inward deflection of the outer wrapper 140 during operation of the gas pump to define the low pressure state of the insulating media 12 within the insulating internal cavity 14. Conversely, engagement of the operable piston 28 with an outer surface 174 of the outer wrapper 140 can serve to prevent outward deflection of the outer wrapper 140 during operation of the operable piston 28. In various embodiments, it is contemplated that the operable piston 28 can engage both the inner and outer surfaces 172, 174 of the outer wrapper 140. The various engagements between the operable piston 28 and the outer wrapper 140 can also include one or more sealing members 170, disposed within the operable piston 28 or adjacent to the operable piston 28 such that when the desired insulation density 120 of the insulating media 12 is achieved, the one or more sealing members 170 can hermetically seal the internal cavity 14 while the operable piston 28 is in the desired position, to maintain the desired insulation density 120 of the insulating media 12.

Referring again to FIGS. 2-9 and 11, a predetermined amount of the insulating media 12 can be disposed within the insulating internal cavity 14 (step 610). As discussed above, the use of a predetermined amount of insulation media assists in the manufacture of the appliance cabinet 145 to achieve the desired insulation density 120 of the insulating media 12. Because the amount of insulating media 12 is known, a density of the insulating media 12 can be determined by adjusting the cavity volume and cavity pressure to place the insulating media 12 into a state that defines the desired insulation density 120. Once the predetermined amount of insulating media 12 is disposed within the insulating cavity, the operable piston 28 is disposed in engagement with the outer wrapper 140 (step 612). Once the operable piston 28 is disposed in engagement with the outer wrapper 140, at least one of the operable piston 28 and the gas pump are operated to define the selected insulating cavity environment that corresponds to the desired insulation density 120 of the insulating media 12 (step 614). As discussed above, the operable piston 28 can be operated to a predetermined location relative to the outer wrapper 140 to define the selected insulating cavity volume. The gas pump can also be operated to define a selected insulating cavity pressure, where the selected insulating cavity volume and selected insulating cavity pressure define the selected insulating cavity environment within which the insulating media 12 is maintained at the desired insulation density 120. As discussed above, the valve 40 can operate in a passive state 44 during operation of only the operable piston 28, or an active state 62 during operation of the gas pump either separately or in conjunction with the operable piston 28.

Referring again to FIGS. 2-9 and 11, during operation of the insulation compaction device 10, the current pressure 98 of the insulating internal cavity 14 is monitored to determine the current insulating cavity pressure (step 616). The current volume 96 of the insulating internal cavity 14 is also monitored to determine when the current volume 96 is substantially equal to the selected chamber volume 32 (step 618). As these monitoring steps (steps 616 and 618) are being conducted, the current density of the insulating media 12 is determined by comparing the predetermined amount of the insulating media 12 to the current pressure 98 and current volume 96 (step 620). Once the current density is substantially equal to the desired insulation density 120 of the insulating media 12, the gas pump and the operable piston 28 are deactivated to maintain the desired insulation density 120 (step 622).

It will be understood by one having ordinary skill in the art that construction of the described device and other components is not limited to any specific material. Other exemplary embodiments of the device disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the device as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present device. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present device, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

The above description is considered that of the illustrated embodiments only. Modifications of the device will occur to those skilled in the art and to those who make or use the device. Therefore, it is understood that the embodiments shown in the drawings and described above is merely for illustrative purposes and not intended to limit the scope of the device, which is defined by the following claims as interpreted according to the principles of patent law, including the Doctrine of Equivalents. 

What is claimed is:
 1. An insulation compaction device for installing insulation within an insulating structure of an appliance, the insulation compaction device comprising: a piston chamber having a sidewall and a base that define an internal cavity; an operable piston selectively engaging the sidewall to selectively define a hermetic seal between the operable piston and the piston chamber, wherein the operable piston is operable to define a selected chamber volume of the internal cavity defined between the operable piston and the piston chamber; a valve positioned proximate the base, the valve defining selective communication between the internal cavity and an exterior of the piston chamber, wherein the valve is selectively operable in a passive state to release gas disposed within the piston chamber to the exterior, wherein the passive state is defined by an equalized pressure within the piston chamber during operation of the operable piston to define the selected chamber volume; and a pump mechanism in communication with the piston chamber via the valve to define an active state of the valve, wherein selective operation of the pump mechanism places the valve in the active state to define a chamber pressure of the internal cavity, the chamber pressure being less than the equalized pressure, and wherein the operable piston and the pump mechanism are at least one of individually operable and simultaneously operable to define a selected piston chamber environment defined by the selected chamber volume and one of the equalized pressure and the chamber pressure.
 2. The insulation compaction device of claim 1, further comprising: a pressure sensor in communication with the internal cavity, wherein the pressure sensor measures the chamber pressure; and a position sensor in communication with the operable piston and the piston chamber, wherein the position sensor measures the selected chamber volume, wherein the pressure sensor and the position sensor cooperate to communicate a current piston chamber environment, wherein at least one of the operable piston and the valve are operated until the current piston chamber environment is substantially equal to the selected piston chamber environment.
 3. The insulation compaction device of claim 2, wherein the piston chamber includes an outer wrapper and an inner liner defining walls of an appliance, and wherein the internal cavity defines an insulating space within the walls.
 4. The insulation compaction device of claim 3, wherein the operable piston includes a back panel of the appliance, wherein the selected chamber volume defines a position of the back panel of the appliance relative to the outer wrapper.
 5. The insulation compaction device of claim 1, wherein the internal cavity includes an insulating media, and wherein operation of the operable piston to the selected chamber volume defines a compressed state of the insulating media within the selected piston chamber environment that corresponds to a desired insulation density.
 6. The insulation compaction device of claim 1, wherein the internal cavity includes an insulating media and wherein operation of the valve in the active state to define the chamber pressure defines a low pressure state of the insulating media within the selected piston chamber environment that corresponds to a desired insulation density.
 7. The insulation compaction device of claim 6, wherein operation of the valve in the active state in conjunction with operation of the operable piston to the chamber volume defines a compressed/low pressure state of the insulating media within the selected piston chamber environment that corresponds to the desired insulation density.
 8. The insulation compaction device of claim 1, wherein the operable piston is operated by a mechanical press.
 9. The insulation compaction device of claim 6, wherein the insulating media comprises at least one of fumed silica, rice husk and glass spheres.
 10. A method for forming an appliance cabinet, the method comprising steps of: forming an insulating cavity between an inner liner and an outer wrapper of an appliance, wherein the inner liner and the outer wrapper define walls of the appliance and the insulating cavity is partially defined between the inner liner and the outer wrapper; disposing a gas valve within at least one of the inner liner and outer wrapper, the gas valve defining a selective communication between the insulating cavity and an exterior of the appliance; disposing a gas pump in communication with the gas valve, wherein the gas pump is in communication with the insulating cavity via the gas valve; providing an operable piston slidably operable against the outer wrapper, wherein selective engagement between the operable piston and the outer wrapper defines a hermetic seal; disposing a predetermined amount of an insulation media within the insulating cavity; disposing the operable piston within the outer wrapper; operating at least one of the operable piston and the gas pump to define a selected insulating cavity environment that corresponds to a desired insulation density, wherein the operable piston operates to a predetermined location relative to the outer wrapper to define a selected insulating cavity volume, and wherein the gas pump is operated to define a selected insulating cavity pressure, wherein the selected insulating cavity volume and the selected insulating cavity pressure define the selected insulating cavity environment within which the insulating media is maintained at the desired insulation density.
 11. The method of claim 10, wherein when only the operable piston is operated to define the desired insulation density, the gas valve selectively operates in a passive state to release gas disposed within the insulating cavity to the exterior, wherein the passive state is defined by an equalized pressure between the insulating cavity and the exterior during operation of the operable piston to define the desired insulation density.
 12. The method of claim 10, wherein the operable piston includes a back panel of the appliance, the back panel defining the insulating cavity with the inner liner and the outer wrapper, wherein when the operable piston is operated to define the selected insulating cavity volume, the outer wrapper and the back panel are attached to maintain the hermetic seal between the back panel and the outer wrapper after the operable piston is removed.
 13. The method of claim 10, wherein when both the operable piston and the gas pump are operated to define the selected insulating cavity environment and the desired insulation density, operation of the operable piston and the gas pump can include at least one of a sequential pattern and a simultaneous pattern, wherein the sequential pattern is defined by sequential operation of the operable piston and the gas pump, and wherein the simultaneous pattern is defined by simultaneous operation of the operable piston and the gas pump.
 14. The method of claim 10, wherein the operable piston is operated by a mechanical press.
 15. The method of claim 10, wherein the insulating media comprises at least one of fumed silica, rice husk and glass spheres.
 16. The method of claim 10, further comprising steps of: monitoring a current pressure of the insulating cavity to determine a current insulating cavity pressure; monitoring a current volume of the insulating cavity to determine when the current volume is substantially equal to a selected chamber volume; determining a current density of the insulating media by comparing the predetermined amount of the insulating media to the current pressure and current volume; and deactivating the gas pump and the operable piston when the current density is substantially equal to the desired insulation density.
 17. A method for forming an insulative member, the method comprising steps of: forming a wrapper for an insulating structure, the wrapper defining an insulating cavity; disposing a predetermined amount of an insulating media into the insulating cavity, the insulating media having a pre-compaction density; and modifying the insulating media to define a desired insulation density by applying a positive compression to and generating a negative compression within the insulating media during a simultaneous compression phase; operating at least the simultaneous compression phase until the insulating media reaches the desired insulation density, the desired insulation density being greater than the pre-compaction density; and sealing the insulating cavity to maintain the desired insulation density of the insulation media within the insulating cavity to form the insulating structure.
 18. The method of claim 17, wherein the positive compression is applied by an operable piston that presses the insulation media, and wherein the negative compression is generated by a gas pump that generates an at least partial vacuum within the insulating cavity.
 19. The method of claim 17, wherein the insulating structure is an appliance cabinet.
 20. The method of claim 17, wherein the insulating media comprises at least one of fumed silica, rice husk and glass spheres. 